EP1829898A1 - Feste katalysatorkomponente und katalysator zur polymerisation von olefin und verfahren zur herstellung von olefinpolymer oder copolymer damit - Google Patents

Feste katalysatorkomponente und katalysator zur polymerisation von olefin und verfahren zur herstellung von olefinpolymer oder copolymer damit Download PDF

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EP1829898A1
EP1829898A1 EP05814411A EP05814411A EP1829898A1 EP 1829898 A1 EP1829898 A1 EP 1829898A1 EP 05814411 A EP05814411 A EP 05814411A EP 05814411 A EP05814411 A EP 05814411A EP 1829898 A1 EP1829898 A1 EP 1829898A1
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Prior art keywords
component
polymerization
compound
group
solid catalyst
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EP05814411A
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French (fr)
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EP1829898A4 (de
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Motoki TOHO CATALYST CO. LTD. HOSAKA
Maki TOHO CATALYST CO. LTD. SATO
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Toho Titanium Co Ltd
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Toho Catalyst Co Ltd
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Priority claimed from JP2004359720A external-priority patent/JP4803636B2/ja
Priority claimed from JP2005010178A external-priority patent/JP4749726B2/ja
Priority claimed from JP2005229423A external-priority patent/JP2007045881A/ja
Application filed by Toho Catalyst Co Ltd filed Critical Toho Catalyst Co Ltd
Publication of EP1829898A1 publication Critical patent/EP1829898A1/de
Publication of EP1829898A4 publication Critical patent/EP1829898A4/de
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
    • C08F4/652—Pretreating with metals or metal-containing compounds
    • C08F4/654—Pretreating with metals or metal-containing compounds with magnesium or compounds thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/65—Pretreating the metal or compound covered by group C08F4/64 before the final contacting with the metal or compound covered by group C08F4/44
    • C08F4/652—Pretreating with metals or metal-containing compounds
    • C08F4/658—Pretreating with metals or metal-containing compounds with metals or metal-containing compounds, not provided for in a single group of groups C08F4/653 - C08F4/657
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F110/04—Monomers containing three or four carbon atoms
    • C08F110/06—Propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/04—Monomers containing three or four carbon atoms
    • C08F210/06—Propene

Definitions

  • the present invention relates to a solid catalyst component and a catalyst for polymerization of olefins capable of maintaining high stereoregularity and yield of the polymer and capable of producing olefin polymers having a high melt flow rate with a given amount of hydrogen (excellent hydrogen response) and having a broad molecular weight distribution, and to a process for producing olefin polymers or copolymers using the solid catalyst component or the catalyst.
  • a solid catalyst component containing magnesium, titanium, an electron-donor compound, and halogen as essential components used for the polymerization of olefins such as propylene has been known.
  • a large number of processs for polymerizing or copolymerizing olefins in the presence of a catalyst for olefin polymerization comprising the above solid catalyst component, an organoaluminum compound, and an organosilicon compound have been proposed.
  • Patent Document 1 JP-A-57-63310
  • Patent Document 2 JP-A-57-63311 propose a process for polymerizing olefins with three or more carbon atoms, in which a catalyst comprising a magnesium compound, a titanium compound, and an organosilicon compound having an Si-O-C bond is used.
  • a catalyst comprising a magnesium compound, a titanium compound, and an organosilicon compound having an Si-O-C bond is used.
  • Patent Document 3 JP-A-63-3010 proposes a catalyst and a process for polymerizing propylene.
  • the catalyst comprises a solid catalyst component prepared by heat treating a powder obtained by contacting dialkoxy magnesium, aromatic dicarboxylic acid diester, aromatic hydrocarbon, and titanium halide; an organoaluminum compound; and an organosilicon compound.
  • Patent Document 4 JP-A-3-234707 discloses a Ziegler-type solid catalyst component for alpha-olefin polymerization obtained by contacting (i) a solid component containing titanium, magnesium, and halogen as essential components, (ii) an organosilicon compound having two or more Si-O bonds, (iii) a vinyl silane compound, and (iv) an organometallic compound of a metal in Group I to III of the Periodic Table.
  • the Patent Document 4 proposes a catalyst for propylene polymerization which comprises the solid catalyst component and an organoaluminum compound and a process for polymerizing propylene in the presence of the catalyst.
  • the polymers produced using these catalysts are used in a variety of applications including formed products such as vehicles and household electric appliances, containers, and films. These products are manufactured by melting polymer powders produced by polymerization and forming the melted polymers using various molds. In manufacturing formed products, particularly, large products by injection molding, melted polymers are sometimes required to have a high fluidity (a melt flow rate: MFR).
  • TPO olefin-based thermoplastic elastomer
  • the melt flow rate greatly depends on the molecular weight of the polymers.
  • hydrogen is generally added as a molecular weight regulator for polymers during polymerization of propylene.
  • a large quantity of hydrogen is usually added to produce low molecular weight polymers having a high melt flow rate.
  • the quantity of hydrogen which can be added is limited because pressure resistance of the reactor is limited for the sake of safety.
  • the partial pressure of monomers to be polymerized has to be decreased, resulting in a decrease in productivity.
  • the use of a large amount of hydrogen also brings about a problem of cost.
  • Patent Document 5 JP-A-1-6006 discloses a solid catalyst component for olefin polymerization containing a dialkoxymagnesium, titanium tetrachloride, and dibutyl phthalate. The catalyst component was proven to be successful to some extent in producing a stereoregular propylene polymer in a high yield. It was indicated, however, that the polymers produced using this catalyst do not have a sufficiently broad molecular weight distribution for producing a biaxial orientation polypropylene film (BOPP).
  • Patent Document 6 JP-A-2001-240634 discloses a process of using an organic cyclic aminosilane compound as an electron donor used in polymerization.
  • Patent Document 7 JP-A-2002-542347 discloses a process of broadening the molecular weight distribution while maintaining catalytic activity by using succinic acid diester as a solid catalyst component. However, this process cannot produce a polymer with sufficient stereoregularity. Further improvement is desired.
  • an object of the present invention is to provide a solid catalyst component and a catalyst for polymerization of olefins capable of maintaining high stereoregularity and yield of the polymer and capable of producing olefin polymers having a high melt flow rate with a given amount of hydrogen (excellent hydrogen response) and having a broad molecular weight distribution, and a process for producing an olefin polymer using the solid catalyst component or the catalyst.
  • a catalyst formed from a solid catalyst component for olefin polymerization obtained by contacting a solid component containing magnesium, titanium, halogen, and an electron donor compound, two types of organosilicon compounds, each having a specific structure, and an organoaluminum compound having a specific structure, and an organoaluminum compound is suitable as a catalyst for polymerizing or copolymerizing olefins as compared with general catalysts.
  • the present invention provides a solid catalyst component for polymerization of olefins obtained by contacting (a) a solid component containing magnesium, titanium, halogen, and an electron donor compound, (b) an organosilicon compound represented by the following formula (1), (c) an organosilicon compound represented by the following formula (2), and (d) an organoaluminum compound represented by the following formula (3).
  • R 1 R 2 N s (R 3 ) 4-s-t Si(OR 4 ) t
  • R 1 individually represents a linear or branched alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, an aryl group, a vinyl group, an allyl group, or an aralkyl group
  • R 2 individually represents a hydrogen atom, a linear or branched alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, an aryl group, a vinyl group, an allyl group, or an aralkyl group
  • R 1 and R 2 being either the same or different, or R 1 and R 2 bonding together to form a cyclic divalent group
  • R 3 individually represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group, an aryl group, a vinyl group, an allyl group, or an aralkyl group
  • R 4 individually represents an al
  • R 5 individually represents a hydrogen atom, an alkyl group having 1 to 20 carbon atoms, a cycloalkyl group, a phenyl group, a vinyl group, or a halogen atom
  • n is 0 or an integer of 1 to 5
  • q is an integer of 1 to 4, provided that when q is 1, at least one of R 5 s is an alkyl group having 2 to 20 carbon atoms, a cycloalkyl group, an aryl group, a vinyl group, or a halogen atom
  • R 6 r AlQ 3-r (3) wherein R 6 represents an alkyl group having 1 to 4 carbon atoms, Q represents a hydrogen atom or a halogen atom, and r represents a real number satisfying the formula 0 ⁇ p ⁇ 3.
  • the present invention further provides a catalyst for polymerization of olefins formed from (A) the above solid catalyst component and (B) an organoaluminum compound represented by the following formula (3), R 6 r AlQ 3-r (3) wherein R 6 represents an alkyl group having 1 to 4 carbon atoms, Q represents a hydrogen atom or a halogen atom, and r represents a real number satisfying the formula 0 ⁇ p ⁇ 3.
  • the present invention further provides a process for producing an olefin polymer or copolymer comprising polymerizing olefins in the presence of the above catalyst for polymerization of olefins.
  • the catalyst using the solid catalyst component for polymerization of olefins of the present invention can highly maintain the stereoregularity and the yield of the polymers and can obtain a greater melt flow rate effect per a given amount of hydrogen (this effect is hereinafter referred to from time to time simply as "hydrogen response") as compared with general catalysts. Therefore, owing to the capability of reducing the amount of hydrogen used for the polymerization and high catalytic activity, the catalyst is expected not only to produce polyolefins for common use at a low cost, but also to be useful in the manufacture of olefin polymers having high functions.
  • an organosilicon compound an external electron donor compound
  • the production cost of the resulting polymer can thus be reduced.
  • olefin polymers with a broad molecular weight distribution can be expected to produce polymers with a high added value suitable for production of a biaxial-orientation polypropylene film (BOPP) and the like.
  • BOPP biaxial-orientation polypropylene film
  • the solid catalyst component (A) (hereinafter referred to from time to time as “component (A)") of the present invention can be obtained by causing a solid component (a) containing magnesium, titanium, halogen, and an electron donor compound (hereinafter referred to from time to time as “component (a)”) to come in contact with an organosilicon compound (b) represented by the above formula (1) (hereinafter referred to from time to time as “component (b)”), an organosilicon compound (c) represented by the above formula (2) (hereinafter referred to from time to time as “component (c)”), and an organoaluminum compound (d) represented by the above formula (3) (hereinafter referred to from time to time as "component (d)").
  • component (a) containing magnesium, titanium, halogen, and an electron donor compound
  • component (a) an organosilicon compound represented by the above formula (1)
  • component (c) represented by the above formula (2)
  • component (d) organoaluminum compound
  • the solid component (a) can be obtained by contacting a magnesium compound (i) (hereinafter referred to from time to time as “component (i)”), a titanium compound (ii) (hereinafter referred to from time to time as “component (ii)”), and an electron donor compound (iii) (hereinafter referred to from time to time as “component (iii)”).
  • a magnesium compound (i) hereinafter referred to from time to time as "component (i)
  • component (ii) titanium compound
  • an electron donor compound (iii) hereinafter referred to from time to time as “component (iii)”
  • an aromatic hydrocarbon compound (iv) (hereinafter referred to from time to time as “component (iv)" is also caused to come in contact with the component (i), the component (ii), and the component (iii).
  • magnesium dihalide As the magnesium compound (i) used for preparing the solid component, magnesium dihalide, dialkyl magnesium, alkylmagnesium halide, dialkoxy magnesium, diaryloxy magnesium, alkoxy magnesium halide, fatty acid magnesium, and the like can be given.
  • magnesium dihalide a mixture of magnesium dihalide and dialkoxy magnesium, and dialkoxy magnesium, particularly dialkoxy magnesium, are preferable.
  • dimethoxy magnesium, diethoxy magnesium, dipropoxy magnesium, dibutoxy magnesium, ethoxymethoxy magnesium, ethoxypropoxy magnesium, and butoxyethoxy magnesium can be given. Of these, diethoxy magnesium is particularly preferable.
  • dialkoxymagnesium compounds may be prepared by reacting metallic magnesium with an alcohol in the presence of a halogen, a halogen-containing metal compound, or the like.
  • the above dialkoxymagnesium compounds may be used either individually or in combination of two or more.
  • the dialkoxymagnesium may be in the form of either granules or powder and either amorphous or spherical in the configuration.
  • the resulting polymer is in the form of a polymer powder having a more excellent particle form and a narrower particle size distribution. This improves operability of the polymer powder produced during polymerization operation and eliminates problems such as clogging caused by fine particles contained in the polymer powder.
  • the spherical dialkoxymagnesium need not necessarily be completely spherical, but may be oval or potato-shaped.
  • the particles may have a ratio (1/w) of the major axis diameter (1) to the minor axis diameter (w) of 3 or less, preferably 1 to 2, and more preferably 1 to 1.5.
  • Dialkoxymagnesium with an average particle size from 1 to 200 ⁇ m can be used.
  • a more preferable average particle size is 5 to 150 ⁇ m.
  • the average particle size is usually 1 to 100 ⁇ m, preferably 5 to 50 ⁇ m, and more preferably 10 to 40 ⁇ m.
  • a powder having a narrow particle size distribution with a small fine and coarse powder content is preferably used.
  • the content of particles with a diameter of 5 ⁇ m or less should be 20% or less, and preferably 10% or less.
  • the content of particles with a diameter of 100 ⁇ m or more should be 10% or less, and preferably 5% or less.
  • the particle size distribution represented by In(D90/D10), wherein D90 is a particle size at 90% of the integrated particle size, and D 10 is a particle size at 10% of the integrated particle size is 3 or less, and preferably 2 or less.
  • the titanium compound (ii) used for preparing of a solid component (a) is one or more compounds selected from the group consisting of tetravalent titanium halides represented by the formula Ti(OR 7 ) n X 4-n , wherein R 7 is an alkyl group having 1 to 4 carbon atoms, X is a halogen atom, and n is an integer of 0 to 4, and alkoxy titanium halides.
  • titanium tetrahalides such as titanium tetrachloride, titanium tetrabromide, and titanium tetraiodide and, as alkoxytitanium halides, methoxytitanium trichloride, ethoxytitanium trichloride, propoxytitanium trichloride, n-butoxytitanium trichloride, dimethoxytitanium dichloride, diethoxytitanium dichloride, dipropoxytitanium dichloride, di-n-butoxytitanium dichloride, trimethoxytitanium chloride, triethoxytitanium chloride, tripropoxytitanium chloride, and tri-n-butoxytitanium chloride.
  • titanium tetrahalides are preferable and a particularly preferable titanium tetrahalide is titanium tetrachloride. These titanium compounds may be used either individually or
  • the electron donor compound (iii) used for preparing the solid component (a) is an organic compound containing an oxygen atom or nitrogen atom.
  • Alcohols, phenols, ethers, esters, ketones, acid halides, aldehydes, amines, amides, nitriles, isocyanates, and organosilicon compounds containing an Si-O-C bond can be given as examples.
  • alcohols such as methanol, ethanol, n-propanol, and 2-ethylhexanol
  • phenols such as phenol and cresol
  • ethers such as methyl ether, ethyl ether, propyl ether, butyl ether, amyl ether, diphenyl ether, 9,9-bis(methoxymethyl)fluorene, and 2-isopropyl-2-isopentyl-1,3-dimethoxypropane
  • monocarboxylic acid esters such as methyl formate, ethyl acetate, vinyl acetate, propyl acetate, octyl acetate, cyclohexyl acetate, ethyl propionate, ethyl butylate, ethyl benzoate, propyl benzoate, butyl benzoate, octyl benzoate, cyclohexyl benzoate, phenyl benzo
  • organosilicon compounds having a Si-N-C bond such as bis(alkylamino)dialkoxysilane, bis(cycloalkylamino)dialkoxysilane, alkyl(alkylamino)dialkoxysilane, dialkylaminotrialkoxysilane, and cycloalkylaminotrialkoxysilane can be given.
  • the esters, particularly aromatic dicarboxylic acid diesters are preferably used.
  • Phthalic acid diesters and phthalic acid diester derivatives are ideal compounds.
  • Specific examples of the phthalic acid diester include the following compounds: dimethyl phthalate, diethyl phthalate, di-n-propyl phthalate, diisopropyl phthalate, di-n-butyl phthalate, diisobutyl phthalate, ethylmethyl phthalate, methyl(isopropyl) phthalate, ethyl(n-propyl) phthalate, ethyl(n-butyl) phthalate, ethyl(isobutyl) phthalate, di-n-pentyl phthalate, diisopentyl phthalate, dineopentyl phthalate, dihexyl phthalate, di-n-heptyl phthalate, di-n-octyl phthal
  • the phthalic acid diester derivatives compounds in which one or two hydrogen atoms on the benzene ring to which the two ester groups of the phthalic diesters bond are substituted with an alkyl group having 1 to 5 carbon atoms or a halogen atom such as a chlorine atom, a bromine atom, and a fluorine atom can be given.
  • the solid catalyst component prepared by using the phthalic acid diester derivatives as an electron donor compound can particularly contribute to a melt flow rate increase with a given amount of hydrogen by increasing hydrogen response, that is, can increase the melt flow rate of polymer by using the same or a smaller amount of hydrogen during the polymerization.
  • the total carbon atom numbers of alkyl groups of the ester used is preferably four or more greater than the total carbon atom numbers of alkyl groups of the other ester.
  • the solid component (a) of the present invention can be preferably prepared by causing the above components (i), (ii), and (iii) to come in contact with each other in the presence of an aromatic hydrocarbon compound (iv).
  • Aromatic hydrocarbon compounds having a boiling point of 50°C to 150°C such as toluene, xylene, and ethylbenzene are preferably used as the component (iv).
  • the aromatic hydrocarbon compounds may be used either individually or in combination of two or more.
  • a process of forming a suspension from the component (i), component (iii), and an aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C, causing the suspension to come in contact with a mixed solution prepared from the component (ii) and the component (iv), and reacting the mixture can be given.
  • a polysiloxane (v) (hereinafter referred to from time to time simply as “component (v)”). Not only stereoregularity or crystallinity of the resulting polymer can be increased, but also production of fine powder of the polymer can be reduced by using the polysiloxane.
  • Polysiloxanes are polymers having a siloxane bond (-Si-O bond) in the main chain and are generally referred to as silicone oil.
  • the polysiloxanes used in the present invention are chain-structured, partially hydrogenated, cyclic, or modified polysiloxanes which are liquid or viscous at normal temperatures with a viscosity at 25°C in the range of 0.02 to 100 cm 2 /s (2 to 10,000 cSt).
  • dimethylpolysiloxane and methylphenylpolysiloxane can be given; as examples of the partially hydrogenated polysiloxanes, methyl hydrogen polysiloxanes with a hydrogenation degree of 10 to 80% can be given; as examples of the cyclic polysiloxanes, hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, 2,4,6-trimethylcyclotrisiloxane, and 2,4,6,8-tetramethylcyclotetrasiloxane can be given; as examples of the modified polysiloxane, higher fatty acid group-substituted dimethylsiloxane, epoxy group-substituted dimethylsiloxane, and polyoxyalkylene group-substituted dimethylsiloxane can be given. Of these, decamethylcyclopenta
  • the solid component (a) can be prepared by causing the above components (i), (ii), and (iii), and, as required, the component (iv) or component (v) to come in contact with each other.
  • the process of preparing this solid component (a) will now be described in detail.
  • One specific example of the process for preparing the solid component comprises suspending the magnesium compound (i) in the tetravalent titanium halide (ii) or the aromatic hydrocarbon compound (iv), and causing the electron donor compound (iii) such as a phthalic acid diester and, as required, the tetravalent titanium halide (ii) to come in contact with the suspension.
  • a spherical solid catalyst component (a) with a sharp particle size distribution can be obtained by using a spherical magnesium compound.
  • a spherical solid component (a) with a sharp particle size distribution can also be obtained without using a spherical magnesium compound if particles are formed by a spray dry process in which a solution or suspension is sprayed and dried using a sprayer, for example.
  • the contact temperature which is a temperature when these components are caused to come into contact with each other, may be either the same as or different from the reaction temperature.
  • the components When the components are caused to come into contact with each other by stirring for preparing the mixture or are dispersed or suspended for a denaturing treatment, the components may be stirred at a comparatively low temperature of around room temperature. A temperature in a range from 40 to 130°C is preferable for obtaining the product by reaction after contact. The reaction does not sufficiently proceed at a reaction temperature below 40°C, resulting in a solid component with inadequate properties. On the other hand, control of the reaction becomes difficult at a temperature above 130°C due to vaporization of the solvent and the like.
  • the reaction time is one minute or more, preferably 10 minutes or more, and still more preferably 30 minutes or more.
  • a process comprising suspending the component (i) in the component (iv), causing the resulting suspension to come in contact with the component (ii), then the component (iii) and component (iv), and causing these components to react and a process comprising suspending the component (i) in the component (iv), causing the resulting suspension to come in contact with the component (iii), then the component (ii), and causing these components to react
  • the solid product thus prepared may be caused to contact with the component (ii) or the components (ii) and (iii) once more or two or more times to improve the performance of the ultimate solid catalyst component.
  • This contacting step is preferably carried out in the presence of the aromatic hydrocarbons (iv).
  • a process of preparing a suspension of the component (i), component (iii), and an aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C a process of preparing a suspension of the component (i), component (iii), and an aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C, causing this suspension to contact with a mixed solution made from the component (ii) and the component (iv), and reacting the mixture.
  • a suspension is prepared from the above component (i), component (iii), and an aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C.
  • a mixed solution is prepared from the above component (ii) and the aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C. The above-described suspension is added to this solution. The resulting mixture is heated and reacted (a first reaction). After the reaction, the solid product is washed with a hydrocarbon compound which is liquid at normal temperatures to obtain a solid product.
  • An additional component (ii) and the aromatic hydrocarbon compound (iv) having a boiling point of 50 to 150°C are caused to come in contact with the washed solid product at a temperature of -20°C to 100°C, then the temperature is raised to react the mixture (a second reaction). After the reaction, the reaction mixture is washed with a hydrocarbon compound which is liquid at normal temperatures 1 to 10 times to obtain a solid component(a) .
  • a process of preparing a suspension from the component (i) and the component (iv), adding a mixed solution prepared from the component (ii) and the component (iv) to the suspension, adding the component (iii) to the resulting mixed solution, and heating the mixture to carry out a reaction (1) can be given.
  • the solid product obtained by the reaction (1) is washed with an aromatic hydrocarbon compound used as the component (iv), caused to come in contact with a mixed solution made from the component (ii) and the component (iv), and heated to carry out a reaction (2) to obtain the solid component (a).
  • a particularly preferable process for preparing the solid component (a) comprises suspending the dialkoxymagnesium (i) in the aromatic hydrocarbon compound (iv) having a boiling point in the range of 50 to 150°C, causing a mixture of the tetravalent titanium halide (ii) and the aromatic hydrocarbon compound (iv) having a boiling point in the range of 50 to 150°C to come in contact with the suspension, and reacting the mixture.
  • one or more electron donor compounds (iii) such as a phthalic acid diester are caused to come in contact with the suspension at a temperature from -20°C to 130°C to carry out the first reaction to obtain a solid product (1).
  • the tetravalent titanium halide (ii) is again caused to come in contact with and reacted with the solid product (1) in the presence of the aromatic hydrocarbon compound at a temperature of -20°C to 100°C to obtain a solid product (2).
  • the intermediate washing and the reaction (2) may be repeated several times.
  • the solid product (2) is washed with a liquid hydrocarbon compound by decantation at an ordinary temperature to obtain the solid component (a).
  • the ratio of the components used for the preparation of the solid component (a) cannot be generically defined, because such a ratio varies according to the process of preparation employed.
  • the tetravalent titanium halide (ii) is used in an amount of 0.5 to 100 mol, preferably 0.5 to 50 mol, still more preferably 1 to 10 mol
  • the electron donor compound (iii) is used in an amount of 0.01 to 10 mol, preferably 0.01 to 1 mol, and still more preferably 0.02 to 0.6 mol
  • the aromatic hydrocarbon compound (iv) is used in an amount of 0.001 to 500 mol, preferably 0.001 to 100 mol, and still more preferably 0.005 to 10 mol
  • the polysiloxane (v) is used in an amount of 0.01 to 100 g, preferably 0.05 to 80 g, and still more preferably 1 to 50 g, for one mol of the magnesium compound (i) .
  • the content of titanium is 1.0 to 8.0 wt%, preferably 2.0 to 8.0 wt%, and still more preferably 3.0 to 8.0 wt%;
  • the content of magnesium is 10 to 70 wt%, preferably 10 to 50 wt%, more preferably 15 to 40 wt%, and particularly preferably 15 to 25 wt%;
  • the content of halogen atoms is 20 to 90 wt%, preferably 30 to 85 wt%, more preferably 40 to 80 wt%, and particularly preferably 45 to 75 wt%;
  • the total amount of electron donor compounds is 0.5 to 30 wt%, preferably 1 to 25 wt%, and particularly preferably 2 to 20 wt%.
  • organosilicon compound (b) represented by the above formula (1) which constitutes the solid catalyst component for olefin polymerization of the present invention a compound represented by the following formula (4) (hereinafter referred to from time to time as “component (b1)”) and a compound represented by the following formula (5) (hereinafter referred to from time to time as “component (b2)”) can be given.
  • component (b1) a compound represented by the following formula (4)
  • component (b2) a compound represented by the following formula (5)
  • R 1 R 2 N s (R 3 ) 4-s-t Si(OR 4 ) t (5) wherein R 1 , R 2 , R 3 , and R 4 are the same as defined above, s is an integer of 1 to 3, t is an integer of 1 or 2, provided that the total of s and t is not more than four.
  • an alkyl group such as a methyl group, an ethyl group, an isopropyl group, an isobutyl group, and a t-butyl group, a cyclopentyl group, and a cyclohexyl group are preferable, with an alkyl group having a secondary or tertiary carbon atom being more preferable, and an alkyl group having a secondary or tertiary carbon atom directly bonding to a silicon atom being particularly preferable.
  • R 4 a methyl group and an ethyl group are preferable.
  • dialkoxysilane in which t is 2 is preferable.
  • organosilicon compound (b1) di-n-propyldimethoxysilane, diisopropyldimethoxysilane, di-n-butyldimethoxysilane, di-n-butyldiethoxysilane, t-butyl(methyl)dimethoxysilane, t-butyl(ethyl)dimethoxysilane, dicyclohexyldimethoxysilane, cyclohexyl(methyl)dimethoxysilane, dicyclopentyldimethoxysilane, cyclopentyl(methyl)diethoxysilane, cyclopentyl(ethyl)dimethoxysilane, cyclopentyl(cyclohexyl)dimethoxysilane, 3-methylcyclohexyl(cyclopentyl)dimethoxysilane, 4-methylcyclohexyl(cyclopentyl)dimethoxysilane,
  • alkyl(alkylamino)alkoxysilane, cycloalkyl(alkylamino)alkoxysilane, alkyl(cycloalkylamino)alkoxysilane, cycloalkyl(cycloalkylamino)alkoxysilane, alkylaminoalkoxysilane, cycloalkylaminoalkoxysilane, polycyclic aminoalkylalkoxysilane, and polycyclic aminoalkoxysilane can be given.
  • polycyclic aminoalkoxysilane bisperhydroquinolinodialkoxysilane and bisperhydroisoquinolinodialkoxysilane and the like can be given.
  • an alkyl group such as a methyl group, an ethyl group, an isopropyl group, an isobutyl group, and a t-butyl group, a cyclopentyl group, and a cyclohexyl group are preferable;
  • R 2 a hydrogen atom, an alkyl group such as a methyl group, an ethyl group, an isopropyl group, an isobutyl group, and a t-butyl group, a cyclopentyl group, and a cyclohexyl group are preferable.
  • R 1 and R 2 bond to each other and form a polycyclic amino group together with N which bonds to Si, and more preferably an alkyl group or a polycyclic amino group having a secondary or tertiary carbon atom.
  • R 3 an alkyl group such as a methyl group, an ethyl group, an isopropyl group, an isobutyl group, and a t-butyl group, a cyclopentyl group, and a cyclohexyl group are preferable, with an alkyl group having a secondary or tertiary carbon atom being more preferable, and an alkyl group having a secondary or tertiary carbon atom directly bonding to a silicon atom being particularly preferable.
  • organosilicon compound (b2) which are preferably used include bis(diethylamino)dimethoxysilane, bis(dipropylamino)dimethoxysilane, bis(diisopropylamino)dimethoxysilane, bis(dibutylamino)dimethoxysilane, bis(diisobutylamino)dimethoxysilane, bis(di-tert-butylamino)dimethoxysilane, bis(dicyclopentylamino)dimethoxysilane, bis(dicyclohexylamino)dimethoxysilane, bis(di-2-methylcyclohexylamino)dimethoxysilane, bisperhydroisoquinolinodimethoxysilane, bisperhydroquinolinodimethoxysilane, bis(ethylpropylamino)dimethoxysilane, bis(ethyl
  • bisperhydroquinolinodimethoxysilane bisperhydroisoquinolinodimethoxysilane, ethyl(tert-butylamino)dimethoxysilane, and ethyl(tert-butylamino)diethoxysilane are particularly preferable.
  • Either one type of these organosilicon compounds (b2) or a combination of two or more types of these compounds can be used in the present invention.
  • organosilicon compound (c) which constitutes the solid catalyst component for olefin polymerization of the present invention
  • component (c1) a compound represented by the following formula (6)
  • component (c2) a compound represented by the following formula (7)
  • [CH 2 CH-(CH 2 ) n1 ] q SiR 5 4-q (6) wherein n1 is an integer of 1 to 5 and R 5 and q are the same as those defined above.
  • (CH 2 CH-) q SiR 5 4-q (7) wherein R 5 and q are the same as defined above.
  • an alkenyl group-containing alkylsilane an alkenyl group-containing cycloalkylsilane, an alkenyl group-containing phenylsilane, an alkenyl group-containing vinylsilane, alkenyl group-containing alkyl halogenated silane, and an alkenyl group-containing halogenated silane can be given.
  • a vinyl group-containing alkylsilane, a vinyl group-containing cycloalkylsilane, a vinyl group-containing phenylsilane, a vinyl group-containing phenylsilane, a vinyl group-containing halogenated silane, and a vinyl group-containing alkyl halogenated silane can be given.
  • the organosilan compounds (c1) specifically, an alkenyl group-containing alkylsilane, an alkenyl group-containing cycloalkylsilane, an alkenyl group-containing phenylsilane, an alkenyl group-containing vinylsilane, alkenyl group-containing alkyl halogenated silane, and an alkenyl group-containing halogenated silane can be given.
  • R 5 is preferably a methyl group, an ethyl group, a vinyl group, or a chlorine atom
  • q is preferably 2 or 3 (i.e. the compound is a dialkenylsilane or a trialkenylsilane)
  • n is 1 or 2 (i.e. the compound is allylsilane or 3-butenylsilane).
  • a particularly preferred compound to be used together with the organosilicon compound (b1) is a diallyldialkylsilane
  • a particularly preferred compound to be used together with the organosilicon compound (b2) is a vinyltrialkylsilane, a divinyldialkylsilane, an allylvinyldialkylsilane, an allyltrialkylsilane, a diallyldialkylsilane, a diallyldihalide, a triallylalkylsilane, and a diallyldialkylsilane.
  • Olefin polymers with a broad molecular weight distribution can be obtained by using the organosilicon compound (b2) and the organosilicon compound (c) in combination.
  • organosilicon compound (c) examples include allyltriethylsilane, allyltrivinylsilane, allylmethyl divinylsilane, allyldimethyl vinylsilane, allylmethyl dichlorosilane, allyltrichlorosilane, allyltribromosilane, diallyldimethylsilane, diallyldiethylsilane, diallyldivinylsilane, diallylmethylvinylsilane, diallylmethylchlorosilane, diallyldichlorosilane, diallyldibromosilane, triallylmethylsilane, triallylethylsilane, triallylvinylsilane, triallylchlorosilane, triallylbromosilane, Tetraallylsilane, di-3-butenylsilane dimethylsilane, di-3-phenylsilane diethylsilane, di-3-but
  • allyldimethyl vinylsilane diallyldimethylsilane, triallylmethylsilane, di-3-butenylsilane dimethylsilane, diallyldichlorosilane, and allyltriethylsilane are particularly preferable.
  • These compounds may be used either individually or in combination of two or more as the organosilicon compound (c).
  • R 6 is preferably an ethyl group or an isobutyl group
  • Q is preferably a hydrogen atom, a chlorine atom, or a bromine atom
  • r is preferably 2 or 3, and particularly preferably 3.
  • organoaluminum compounds (d) triethylaluminum, diethylaluminum chloride, triisobutylaluminum, diethylaluminum bromide, and diethylaluminum hydride can be given. These compounds may be used either individually or in combination of two or more. Of these, triethylaluminum and triisobutylaluminum are preferable.
  • the solid catalyst component (A) of the present invention there are a solid catalyst component (A1) (hereinafter referred to from time to time as “component (A1)”) prepared by a process of using the organosilicon compound (b1) (hereinafter referred to from time to time as “process 1”) and a solid catalyst component (A2) (hereinafter referred to from time to time as “component (A2)”) prepared by a process of using the organosilicon compound (b2) (hereinafter referred to from time to time as "process 2").
  • component (A1) hereinafter referred to from time to time as “component (A1)
  • process 1 a process of using the organosilicon compound (b1)
  • component (A2) hereinafter referred to from time to time as “component (A2)
  • the solid catalyst component (A1) contains magnesium, titanium, a halogen, the component (b1), and the component (c1) or a polymer of the component (c1), and can be obtained by causing the component (b1), the component (c1), and the component (d) to come in contact with the solid component (a).
  • the component (c1) may be ultimately present in the solid catalyst component in the form of a polymer, the component (c1) is polymerized and added when the components (a), (b1), (c1), and (d) are caused to come in contact with each other.
  • the components (a), (b1), (c1), and (d) are caused to come in contact with each other in the presence of an inert solvent.
  • an inert solvent an aliphatic hydrocarbon such as hexane, heptane, and cyclohexane, an aromatic hydrocarbon such as toluene, xylene, and ethylbenzene, and the like can be used.
  • a process of first contacting the component (a) with the component (b1) or the component (c1), then causing the component (d) to come in contact with the resulting mixture is preferable.
  • a process of first contacting the component (a) with the component (c1), and causing the component (b1) and the component (d) to come in contact with the resulting mixture is more preferable.
  • the operation of contacting the component (a) with the component (d) may be carried out in the presence of the component (b1) or the component (c1). After contacting each component as mentioned above, the mixture is washed with an inert solvent such as heptane to remove unnecessary components.
  • a mixture containing the component (d) must be washed particularly sufficiently because the component (d) contained in a solid catalyst component lowers the catalytic activity over time. After causing the components (b1), (c1), and (d) to come in contact with the component (a), the components (b1), (c1), and (d) may be repeatedly caused to come in contact with the mixture once again or two or more times.
  • Causing a polysiloxane (e) to come in contact when the above-mentioned organosilicon compound (b1), organosilicon compound (c1), and organoaluminum compound (d) are caused to come in contact with the solid component (a) is preferable in order to obtain a polymer with a broad molecular weight distribution, improved stereoregularity or crystal properties, and to reduce production of fine powder in the polymer.
  • polysiloxane (e) used when preparing the solid component (a) can be used as the polysiloxane (e).
  • each component used is not specifically limited inasmuch to the extent that the effect of the present invention is not adversely affected.
  • the component (b1) and the component (c1) are used in an amount of 0.5 to 10 mols, and preferably 1 to 5 mols, per one mol of titanium atom in the component (a).
  • the component (d) is used in an amount of 1 to 15 mols, preferably 3 to 10 mols, and particularly preferably 4 to 7 moles, per one mol of the component (a).
  • the temperature at which the components are caused to come in contact is -10°C to 100°C, preferably 0°C to 80°C, and particularly preferably 25°C to 75°C.
  • the contact is carried out for 1 minute to 10 hours, preferably for 10 minutes to 5 hours, and particularly preferably for 30 minutes to 2 hours.
  • the component (c1) particularly polymerizes according to the conditions under which the component (c1) is caused to come in contact, thereby producing a polymer. When the temperature is 30°C or more, the component (c1) starts to polymerize and improves crystal properties and catalytic activity of the resulting olefin polymer.
  • the solid catalytic component (A1) obtained by the above process 1 contains magnesium, titanium, halogen, the component (b1), and the component (c1) or the polymer thereof.
  • the content of magnesium is from 10 to 70 wt%, and preferably from 10 to 50 wt%
  • the content of titanium is from 1.0 to 8.0 wt%, and preferably from 2.0 to 8.0 wt%
  • the content of halogen is from 20 to 90 wt%, and preferably from 30 to 85 wt%
  • the content of the component (b1) is from 1.0 to 50 wt%, and preferably from 1.0 to 30 wt%
  • the component (c1) or the polymer thereof is from 1.0 to 50 wt%, and preferably from 1.0 to 30 wt%.
  • the solid catalyst component (A2) is obtained by the process 2, wherein the organosilicon compound (b2), the organosilicon compound (c) represented by the above formula (2), and the organoaluminum compound (d) represented by the above formula (3) are caused to come in contact with the solid component (a) containing magnesium, titanium, halogen, and an electron donor compound.
  • organosilicon compound (c) preferably used in the process 2, vinyltrimethylsilane, vinyltriethylsilane, vinylmethyldichlorosilane, vinyltrichlorosilane, vinyltribromosilane, divinyldimethylsilane, divinyldiethylsilane, divinylmethylchlorosilane, divinyldichlorosilane, divinyldibromosilane, trivinylmethylsilane, trivinylethylsilane, trivinylchlorosilane, trivinylbromosilane, tetra-vinylsilane, allyltriethylsilane, allyltrivinylsilane, allylmethyldivinylsilane, allyldimethylvinylsilane, allylmethyldichlorosilane, allyltrichlorosilane, allyltribromosilane, diallyldimethylsilane, vinyl
  • vinyltrimethylsilane divinyldimethylsilane, allyldimethylvinylsilane, diallyldimethylsilane, triallylmethylsilane, di-3-butenyldimethylsilane, diallyldichlorosilane, allyltriethylsilane, and the like are particularly preferable.
  • Either one type of these organosilicon compounds (c) or a combination of two or more types of these compounds can be used in the present invention.
  • the solid catalyst component (A2) is obtained by causing the component (b2), the component (c), and the component (d) to come in contact with the solid component (a).
  • the components (a), (b2), (c), and (d) are caused to come in contact with each other in the presence of an inert solvent.
  • an inert solvent an aliphatic hydrocarbon such as hexane, heptane, and cyclohexane, an aromatic hydrocarbon such as toluene, xylene, and ethylbenzene, and the like can be used.
  • a process of first contacting the component (a) with the component (b2) or the component (c), then causing the component (d) to come in contact with the resulting mixture is preferable.
  • the latter contact is carried out in the presence of the component (b2) or the component (c).
  • the mixture is washed with an inert solvent such as heptane to remove unnecessary components.
  • a mixture containing the component (d) must be washed particularly sufficiently because the component (d) contained in a solid catalyst component causes to lower the catalytic activity over time.
  • the components (b2), (c), and (d) may be repeatedly caused to come in contact with the mixture once again or two or more times.
  • Component (b2) Component (c) (1) bisperhydroisoquinolinodimethoxysilane diallyldimethylsilane (2) bisperhydroisoquinolinodimethoxysilane diallyldimethylsilane (3) ethyl(tert-butylamino)dimethoxysilane diallyldimethylsilane (4) bisperhydroisoquinolinodimethoxysilane allyldimethylvinylsilane (5) bisperhydroisoquinolinodimethoxysilane triallylmethylsilane (6) ethyl(tert-butylamino)diethoxysilane diallyldimethylsilane (7) ethyl(tert-butylamino)diethoxysilane allyldimethylvinylsilane
  • the ratio of each component used is arbitrarily determined to the extent that the effect of the present invention is not adversely affected.
  • the component (b2) and the component (c) are used in an amount of 0.2 to 10 mols, and preferably 0.5 to 5 mols, per one mol of titanium atom in the component (a).
  • the component (d) is used in an amount of 0.5 to 15 mols, preferably 1 to 10 mols, and particularly preferably 1.5 to 7 moles, per one mol of titanium atom in the component (a).
  • the temperature at which the components are caused to come in contact is -10°C to 100°C, preferably 0°C to 90°C, and particularly preferably 20°C to 80°C.
  • the contact is carried out for 1 minute to 10 hours, preferably for 10 minutes to 5 hours, and particularly preferably for 30 minutes to 2 hours.
  • the component (c) particularly polymerizes according to the conditions under which the component (c) is caused to come in contact, thereby producing a polymer. When the temperature is 30°C or more, the component (c) starts to polymerize. A part or the whole of the component (c) becomes a polymer and improves crystal properties and catalytic activity of the resulting olefin polymer.
  • the solid catalytic component (A2) obtained by the above process 2 contains magnesium, titanium, halogen, the component (b2), and the component (c) or the polymer thereof.
  • the content of magnesium is from 10 to 70 wt%, and preferably from 10 to 50 wt%;
  • the content of titanium is from 1.0 to 8.0 wt%, and preferably from 2.0 to 8.0 wt%;
  • the content of halogen is from 20 to 90 wt%, and preferably from 30 to 85 wt%;
  • the content of the component (b2) is from 1.0 to 50 wt%, and preferably from 1.0 to 30 wt%;
  • the component (c) is from 1.0 to 50 wt%, and preferably from 1.0 to 30 wt%.
  • organoaluminum compound (B) used for preparing the catalyst for polymerization of olefins of the present invention the same organoaluminum compounds as the component (d) mentioned above, preferably triethylaluminum and triisobutylaluminum can be used.
  • an organosilicon compound (C) (hereinafter referred to from time to time simply as “component (C)") may be used for preparing the catalyst for polymerization of olefins of the present invention.
  • component (C) organosilicon compound
  • the catalyst for polymerization of olefins can maintain high activity and high stereoregularity without using the component (C)
  • the catalyst can exhibit even higher activity and higher stereoregularity if the component (C) is used in combination with the component (A1) or (A2) and the component (B).
  • the same compounds as previously given as examples of the component (b) or the component (e), preferably ethyl(t-butylamino)dimethoxysilane, ethyl(t-butylamino)diethoxysilane, di-n-propyldimethoxysilane, diisopropyldimethoxysilane, dicyclopentyldimethoxysilane, dicyclohexyldimethoxysilane, cyclohexylmethyldimethoxysilane, and cyclopentylcyclohexyldimethoxysilane can be given.
  • Olefins are polymerized or copolymerized by random or block copolymerization in the presence of the catalyst for olefin polymerization of the present invention.
  • olefins used in the polymerization olefins such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, and vinyl cyclohexane can be used either individually or in combination of two or more. Of these, ethylene, propylene, and 1-butene can be suitably used.
  • a particularly preferable olefin is propylene. Propylene may be copolymerized with one or more other olefin monomers.
  • ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, vinyl cyclohexane, and the like can be used either individually or in combination of two or more. Of these, ethylene and 1-butene can be suitably used.
  • random copolymerization of polymerizing propylene with a small amount of ethylene as a comonomer in one step, and propylene-ethylene block copolymerization of polymerizing only propylene in a first step (first polymerization vessel) and copolymerizing propylene and ethylene in a second step (second polymerization vessel) can be given as typical processes.
  • the catalyst of the present invention comprising the components (A1) or (A2) and component (B), or component (C) is effective in both the random copolymerization and block copolymerization for improving the catalytic activity, stereoregularity, and/or hydrogen response, copolymerization performance, and properties of resulting copolymers.
  • the random copolymerization of propylene and ethylene an excellent copolymer with a high degree of randomness with a high ethylene content of 5 to 10 wt% can be obtained.
  • a copolymer with a high rubber content can be obtained by the block copolymerization of ethylene and propylene.
  • An alcohol may be added to the polymerization reaction system in order to prevent formation of gel in the finished product, particularly when shifting from homopolymerization of propylene to the block copolymerization.
  • the alcohol ethyl alcohol and isopropyl alcohol can be given. These alcohols are used in an amount of 0.01 to 10 mols, and preferably 0.1 to 2 mols, for one mol of the component (B).
  • the ratio of each component used is arbitrarily selected to the extent that the effect of the present invention is not adversely affected.
  • the component (B) is used in an amount of 1 to 2,000 mols, and preferably 50 to 1,000 mols, per one mol of titanium atom in the component (A1) or the component (A2).
  • the component (C) is used in an amount of 0.002 to 10 mols, preferably 0.01 to 2 mols, and particularly preferably 0.1 to 0.5 mol, per one mol of the component (B).
  • the order of contact of the components is not arbitrarily determined, it is desirable to first add the organoaluminum compound (B) to the polymerization system and then cause the solid catalyst components (A1) or (A2) to come in contact with the organoaluminum compound (B).
  • the component (C) is used, the organoaluminum compound (B) is first added to the polymerization system, then the component (C) is added, following which the solid catalyst components (A1) or (A2) is caused to come in contact with the mixture.
  • polymerization can be carried out either in the presence or in the absence of an organic solvent.
  • Olefin monomers such as propylene may be used either in a gaseous state or in a liquid state.
  • the polymerization reaction is preferably carried out at a temperature of 200°C or less, and preferably at 100°C or less, under a pressure of 10 MPa or less, and preferably 6 MPa or less.
  • Either a continuous polymerization system or a batch polymerization system may be used for the polymerization reaction.
  • the polymerization can be completed either in one step or in two or more steps.
  • main polymerization In polymerizing olefins using the catalyst formed from the component (A1) or (A2) and the component (B), or the component (C) (hereinafter may be referred to from time to time as "main polymerization"), it is desirable to preliminarily polymerize the olefins prior to the main polymerization to further improve the catalytic activity, stereoregularity, properties of resulting polymer particles, and the like.
  • monomers such as styrene can be used in the preliminary polymerization.
  • the component (B) and/or the component (C) are caused to come in contact to form the catalyst.
  • the order of contact of the components and monomers in carrying out the preliminary polymerization is optional, it is desirable to first add the component (B) to the preliminary polymerization system in an inert gas or olefin gas atmosphere such as propylene, cause the component (A1) or (A2) to contact the component (B), and then cause one or more olefins such as propylene to contact the mixture.
  • the preliminary polymerization temperature is from -10°C to 70°C, and preferably from 0°C to 50°C.
  • the polymerization of olefins in the presence of the olefin polymerization catalyst of the present invention can produce olefin polymers in a higher yield than in the polymerization using a conventional catalyst, while maintaining a higher stereoregularity of the polymer and improved hydrogen response.
  • the suspension was added to a solution of 450 ml of toluene and 300 ml of titanium tetrachloride in another 2,000 ml round bottom flask equipped with a stirrer, of which the internal atmosphere had been sufficiently replaced with nitrogen gas.
  • the suspension was reacted at 5°C for one hour.
  • the resulting reaction mixture was washed four times with 1,300 ml of toluene at 80°C.
  • 1,200 ml of toluene and 300 ml of titanium tetrachloride the reaction mixture was heated to 110°C and reacted for two hours with stirring (second reaction). The intermediate washing and the second reaction was repeated once more.
  • the resulting reaction mixture was washed seven times with 1,300 ml of heptane at 40°C, filtered, and dried to obtain a solid component in the form of a powder. The content of titanium in the solid component was measured and found to be 2.9 wt%.
  • the catalytic activity, the heptane insoluble components (HI, wt%), the melt index (MI, g-PP/10 min), and the xylene-soluble components at 23°C (XS, wt%) of the resulting polymer were measured. The results are also shown in Table 3.
  • catalytic activity produced polymer F ⁇ g / solid catalyst component g / hour
  • the xylene-soluble components (XS, wt%) of the polymer was determined as follows.
  • the melt index (MI) which indicates the melt flow rate of the polymer was determined according to the process conforming to ASTM D1238 or JIS K7210.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that triallylmethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that diallyldichlorosilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that allyldimethylvinylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that allyltriethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that cyclohexylmethyldimethoxysilane instead of t-butylethyldimethoxysilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that dicyclopentyldimethoxysilane instead of t-butylethyldimethoxysilane. The results are shown in Table 3.
  • the solid was separated from the liquid at 95°C, washed twice with 48 ml of toluene, and again treated with diisobutyl phthalate and titanium tetrachloride under the same conditions as above. The resulting solid was washed eight times with 48 ml of hexane, filtered, and dried to obtain a solid catalyst component in the form of a powder. The content of titanium in the solid catalyst component was analyzed and found to be 2.1 wt%.
  • a solid catalyst component was prepared in the same manner as in Example 1 except for using the solid component obtained above.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except for using the solid catalyst component prepared above. The results are shown in Table 3.
  • the resulting reaction solution was added dropwise over one hour to 200 ml of titanium tetrachloride maintained at -20°C in another 500 ml round bottom flask equipped with a stirrer, of which the internal atmosphere had been sufficiently replaced with nitrogen gas.
  • the mixed solution was heated to 110°C over four hours and 2.68 ml of diisobutyl phthalate was added. The mixture was reacted for two hours. After the reaction, the liquid portion was removed by filtration. The remaining solid was washed with decane and hexane at 110°C until no free titanium compounds were detected, filtered, and dried to obtain a solid catalyst component in the form of a powder.
  • the content of titanium in the solid catalyst component was measured and found to be 3.1 wt%.
  • a solid catalyst component was prepared in the same manner as in Example 1 except for using the solid component obtained above.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except for using the solid catalyst component prepared above. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that allyltrimethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 1, except that vinyltrimethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3.
  • Example 3 A polymerization catalyst was formed and polymerization was carried out in the same manner as in Example 1, except that divinyldimethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 3. TABLE 3 Polymerization activity g-PP/g-cat HI wt% MI g/10min XS wt% Example 1 63,600 98.0 19 1.7 Example 2 65,100 97.6 36 2.3 Example 3 52,000 97.7 26 2.0 Example 4 64,400 97.7 33 1.9 Example 5 59,600 97.6 25 2.0 Example 6 62,500 97.8 35 2.1 Example 7 64,800 98.1 27 1.7 Example 8 50,900 97.3 36 2.6 Example 9 52,300 97.2 31 3.0 Comparative Example 1 32,000 97.5 15 2.2 Comparative Example 2 53,300 97.5 11 2.3 Comparative Example 3 56,800 97.5 12 2.2
  • the suspension was added to a solution of 450 ml of toluene and 300 ml of titanium tetrachloride in another 2,000 ml round bottom flask equipped with a stirrer, of which the internal atmosphere had been sufficiently replaced with nitrogen gas.
  • the suspension was reacted at 5°C for one hour.
  • the resulting reaction mixture was washed four times with 1,300 ml of toluene at 80°C.
  • 1,200 ml of toluene and 300 ml of titanium tetrachloride the reaction mixture was heated to 110°C and reacted for two hours with stirring (second reaction). The intermediate washing and the second reaction was repeated once more.
  • the resulting reaction mixture was washed seven times with 1,300 ml of heptane at 40°C, filtered, and dried to obtain a solid component in the form of a powder. The content of titanium in the solid component was measured and found to be 2.9 wt%.
  • the resulting reaction mixture was washed seven times with 100 ml of heptane at 30°C to obtain a solid catalyst component.
  • the solid catalyst component was analyzed to find that the titanium content was 3.4 wt% and the silane content was 3.0 wt%.
  • the catalytic activity, the heptane insoluble components (HI, wt%), the melt index (MI, g-PP/10 min), and the xylene-soluble components at 23°C (XS, wt%) of the resulting polymer were measured. The results are also shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that triallylmethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that diallyldichlorosilane was used instead of diallyldimethylsilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that allyldimethylvinylsilane was used instead of diallyldimethylsilane. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that allyltriethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that cyclohexylmethyldimethoxysilane was used instead of t-butylethyldimethoxysilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that dicyclopentyldimethoxysilane was used instead of t-butylethyldimethoxysilane.
  • the results are shown in Table 4.
  • the solid was separated from the liquid at 95°C, washed twice with 48 ml of toluene, and again treated with diisobutyl phthalate and titanium tetrachloride under the same conditions as above. The resulting solid was washed eight times with 48 ml of hexane, filtered, and dried to obtain a solid catalyst component in the form of a powder. The content of titanium in the solid catalyst component was analyzed and found to be 2.1 wt%.
  • a solid catalyst component was prepared in the same manner as in Example 10 except for using the solid component obtained above.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 10, except for using the solid catalyst component prepared above. The results are shown in Table 4.
  • the resulting reaction solution was added dropwise over one hour to 200 ml of titanium tetrachloride maintained at -20°C in another 500 ml round bottom flask equipped with a stirrer, of which the internal atmosphere had been sufficiently replaced with nitrogen gas.
  • the mixed solution was heated to 110°C over four hours and 2.68 ml of diisobutyl phthalate was added. The mixture was reacted for two hours. After the reaction, the liquid portion was removed by filtration. The remaining solid was washed with decane and hexane at 110°C until no free titanium compounds were detected, filtered, and dried to obtain a solid catalyst component in the form of a powder.
  • the content of titanium in the solid catalyst component was measured and found to be 3.1 wt%.
  • a solid catalyst component was prepared in the same manner as in Example 10 except for using the solid component obtained above.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 10, except for using the solid catalyst component prepared above. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that allyltrimethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that vinyltrimethylsilane was used instead of diallyldimethylsilane. The results are shown in Table 4.
  • Example 10 A solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 10, except that divinyldimethyl was used instead of diallyldimethylsilane.
  • the results are shown in Table 4.
  • Example 10 77,900 97.9 20 4.8
  • Example 11 80,300 97.6 34 2.5
  • Example 12 64,000 97.8 22 1.9
  • Example 13 78,100 97.5 31 2.0
  • Example 14 69,500 97.4 29 2.2
  • Example 15 65,000 97.6 17 2.3
  • Example 16 70,300 98.0 12 1.9
  • Example 18 62,500 97.3 29 2.9
  • Comparative Example 4 39,200 97.5 15 2.1 Comparative Example 5 64,700 97.4 12 2.3 Comparative Example 6 70,100 97.
  • the resulting suspension was maintained at 10°C.
  • 20 ml of titanium tetrachloride was added to the suspension while cooling the flask to maintain the temperature of the suspension at 10°C.
  • the mixture was stirred at 10°C for one hour.
  • the mixture was heated to 90°C and reacted for one hour while stirring at 90°C.
  • the resulting reaction mixture was washed four times with 100 ml of toluene at 80°C.
  • reaction mixture After the addition of 20 ml of titanium tetrachloride and 80 ml of toluene, the reaction mixture was heated to 100°C and reacted for one hour while stirring. After the reaction, the resulting reaction mixture was washed seven times with 100 ml of n-heptane at 40°C. Solid was separated from liquid. The content of titanium in the solid component was measured and found to be 2.8 wt%.
  • Polydispersity index (PI) was measured using a dynamic stress rheometer manufactured by Rheometric Scientific, Inc. using a disk with a thickness of 1.0 mm.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that the amount of bisperhydroisoquinolinodimethoxysilane was reduced to 1.9 g from 3.9 g, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.2 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 2.0 g of ethyl(tert-butylamino)dimethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.7 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 2.3 g of ethyl(tert-butylamino)diethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.6 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 3.9 g of bisperhydroisoquinolinodimethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.0 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 0.4 g of allyldimethylvinylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.1 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 0.6 g of triallylmethylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.0 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 2.3 g of ethyl(tert-butylamino)diethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, 0.6 g of diallyldichlorosilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component. The content of titanium in the resulting solid catalyst component was 2.7 wt%. The polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 2.3 g of ethyl(tert-butylamino)diethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, 0.5 g of allyltriethylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component. The content of titanium in the resulting solid catalyst component was 2.6 wt%. The polymerization results are shown in Table 5.
  • a solid component and a solid catalyst component were prepared in the same manner as in Example 19, except that 2.5 g of diisobutyl phthalate was used instead of 2.5 g of di-n-butyl phthalate, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.0 wt%.
  • the polymerization results are shown in Table 5.
  • the polymerization was carried out in the same manner as in Example 19, except that 0.013 mmol of cyclohexylmethyldimethoxysilane was further added when forming the polymerization catalyst.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 24, except that 2.3 g of ethyl(tert-butylamino)diethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.7 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 20 using the solid component prepared in the Example 25, except that 2.3 g of ethyl(tert-butylamino)diethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.7 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 0.4 g of divinyldimethylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.2 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 19, except that 0.4 g of vinyltrimethylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.1 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 19 using the solid component prepared in the Example 23, except that 0.4 g of vinyltrimethylsilane was used instead of 0.5 g of diallyldimethylsilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 2.3 wt%.
  • the polymerization results are shown in Table 5.
  • a solid catalyst component was prepared in the same manner as in Example 28 using the solid component prepared in the Example 19, except that 2.0 g of cyclohexylmethyldimethoxysilane was used instead of 3.9 g of bisperhydroisoquinolinodimethoxysilane, and a polymerization catalyst was formed from the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 1.9 wt%.
  • the polymerization results are shown in Table 5.
  • Example 19 Using the solid component prepared in Example 19, a solid catalyst component was prepared, a polymerization catalyst was formed, and polymerization was carried out in the same manner as in Example 19, except that use of the solid component prepared in the Example 19 was omitted when preparing the solid catalyst component.
  • the content of titanium in the resulting solid catalyst component was 1.9 wt%.
  • the polymerization results are shown in Table 5.
  • a polymerization catalyst was formed by adding triethylaluminum (TEAL) and the solid catalyst component prepared in Example 1 in an amount, in terms of the titanium atom contained therein, of 0.0035 mmol, while maintaining the atmosphere of an ethylene-propylene mixed gas.
  • TEAL triethylaluminum
  • the mol ratio of Ti to TEAL (Ti:TEAL) in the solid catalyst component was 1:600.
  • a preliminary polymerization was carried using only propylene at 20°C under 0.1 MPaG for 30 minutes.
  • Example 35 A propylene-ethylene random copolymer was prepared in the same manner as in Example 35, except for using the solid catalyst component prepared in Comparative Example 1. The results are shown in Table 6. TABLE 6 Example 35 Comparative Example 10 Polymerization activity (g/g-cat.) 14,000 8,300 Ethylene content (wt%) 2.1 1.9 Heptane insoluble components (wt%) 0.3 3.8 MI (g/10 min) 3.2 2.8 Melting point (°C) 148 152
  • TEAL triethylaluminum
  • the mol ratio of Ti to TEAL (Ti:TEAL) in the solid catalyst component was 1:700.
  • preliminary polymerization was carried out for five minutes at 20°C, followed by bulk polymerization of propylene at 70°C for one hour.
  • a mixed gas of ethylene, propylene, and hydrogen at a molar ratio of 0.7:1:0.03 was supplied under a pressure of 1.2 MPa at 70°C for two hours to effect a vapor phase reaction, thereby obtaining a propylene-ethylene block copolymer with a rubber portion content of about 30 wt%.
  • the polymerization activity, ethylene content of the resulting propylene-ethylene block copolymer, EPR content, PP section MI, PP section xylene insoluble components, and MI are shown in Table 7.
  • a propylene-ethylene random copolymer was prepared in the same manner as in Example 36, except for using the solid catalyst component prepared in Comparative Example 1. The results are shown in Table 7. TABLE 7 Example 36 Comparative Example 11 Homopolymerization activity (g/g-cat.) 54,200 32,000 Ethylene content in EPR (wt%) 48 44 EPR content (wt%) 33 30 Copolymerization activity 74,800 49,200 Homopolymer MI (g/10 min) 160 150 Copolymer MI (g/10 min) 18 20
  • a polymerization catalyst was formed by adding triethylaluminum (TEAL) and the solid catalyst component prepared in Example 11 in an amount, in terms of the titanium atom contained therein, of 0.0035 mmol, while maintaining the atmosphere of an ethylene-propylene mixed gas.
  • TEAL triethylaluminum
  • the mol ratio of Ti to TEAL (Ti:TEAL) in the solid catalyst component was 1:600.
  • a preliminary polymerization was carried out using only propylene at 20°C under 0.1 MPaG for 30 minutes.
  • a propylene-ethylene random copolymer was prepared in the same manner as in Example 37, except for using the solid catalyst component prepared in Comparative Example 4. The results are shown in Table 8. TABLE 8 Example 37 Comparative Example 12 Polymerization activity (g/g-cat.) 17,000 10,100 Ethylene content (wt%) 2.0 1.8 Heptane soluble components (wt%) 0.4 3.5 MI (g/10 min) 3.5 2.7 Melting point (°C) 148 150
  • TEAL triethylaluminum
  • the mol ratio of Ti to TEAL (Ti:TEAL) in the solid catalyst component was 1:700.
  • preliminary polymerization was carried out for five minutes at 20°C, followed by bulk polymerization of propylene at 70°C for one hour.
  • a mixed gas of ethylene, propylene, and hydrogen at a molar ratio of 0.7:1:0.03 was supplied under a pressure of 1.2 MPa at 70°C for two hours to effect a vapor phase reaction, thereby obtaining a propylene-ethylene block copolymer with a rubber portion content of about 30 wt%.
  • the polymerization activity, ethylene content of the resulting propylene-ethylene block copolymer, EPR content, PP section MI, PP section xylene insoluble components, and MI are shown in Table 9.
  • Example 38 A propylene-ethylene random copolymer was prepared in the same manner as in Example 38, except for using the solid catalyst component prepared in Comparative Example 4. The results are shown in Table 9. TABLE 9 Example 38 Comparative Example 13 Homopolymerization activity (g/g-cat.) 66,400 38,500 Ethylene content in EPR (wt%) 48 44 EPR content (wt%) 30 29 Copolymerization activity 89,600 56,800 Homopolymer MI (g/10 min) 150 145 Copolymer MI (g/10 min) 20 22
  • the catalyst of the present invention is used for random copolymerization of propylene and ethylene, a random copolymer with a high ethylene content and high random properties can be obtained under the same polymerization conditions, while a block copolymer with a high EPR content can be obtained under the same polymerization conditions.
  • the catalyst has superior hydrogen response, general purpose polyolefin can be produced at a low cost.
  • the catalyst is expected to be useful also in the manufacture of olefin polymers having sophisticated functions.
  • polymers suitable for production of a biaxial-orientation polypropylene film can be provided.

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